Weaving pile fabric including jaspe



June 23, 1959 F. w. E. HO'ESELBARTH 2,891,582

WEAVING FILE FABRIC INCLUDING JASPE 5 Sheets-Sheet 1 Filed Aug 24. 1955 INVENTOR FRANK W. E. HOESELBARTH BY g I TTORNEYS June 23, 1959 F. w. E. HOESELBARTH 2,891,582

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INVENTOR FRANK W E. HOESELBARTH June 23, 1959 F. w. E; HOES ELBARTH 2,891,532

WEAVING FILE FABRIC IbgUbING JASPE 5 Sheets-Sheet 3 Filed Aug. 24, 1955 flu 4/ M 3 l 0/ 2 2 I 5 H a v v 4 9w 7 7 l la y a INVENTOR FRANK w. E. HOESELBARTH ATTORNEYS June 23, 1959 F. w. E. HOESELBARTH 2,891,582

'wEAvmc PILE FABRIC INCLUDING JASPE Filed Aug. 24. 1955 5 Sheets-Sheet 4 k INVENTOR FRANK w. E. HOESELBARTH BY &

ORNEYS June 23, 1959 F. w. E. HOESELBARTH 2,891,582

WEAVING FILE FABRIC- mcwmm JASPE iled Aug. 24. 1955 5 Sheets-Sheet 5 $3 I INVENTOR FRANK W E. HOESELBARTH W 7 BY I United States Patent WEAV'ING PlL'E FABRIC INCLUDING JASPE Frank W. E. Hoeselharth, Carlisle, Pa., 'assignor to C. H.

Masland & Sons, Carlisle, Pa., a corporation of Pennsylvania Application August 24, 1955, Serial No. 530,313

7 Claims. (Cl. 139-39) The present invention relates to weaving pile fabrics of the character of carpets and rugs, and to the fabrics thus produced. The invention is particularly applicable to velvet or tapestry weaving but can also be applied to Wilton or Brussels weaving.

The present application is being divided and the subject matter relating to the pile fabric is embodied in my copending application Serial 603,520, filed August 13, 1956, for Jaspe Pile Fabric.

A purpose of the invention is to obtain pattern effects Without using a jacquard mechanism and thus to secure higher speeds of weaving.

A further purpose is to secure rotation of two or more separate pile warp ends carried through the same heddle eye and in the same dent by frictional engagement so as to place one end in a predominant position in one pile projection and another end in a predominant position in another pile projection.

A further purpose is to secure a pile fabric having a pattern effect without the necessity of using wires, desirably weaving .at increased speed. v

A further purpose is to crowd the pile projections by varying the thread-in in different'dents or courses so as to secure a buckling effect in the face of the fabric which gives a pronounced texturing, and breaks up any lining effect which would otherwise be seen in prior art practice.

A further purpose is to obtain a bind in a multiple pile velvet weave beneath at least two upper wefts, rather than merely by a single upper weft in a two shot carpet.

Further purposes appear in the specification and in the claims.

In the drawingsl have chosen to illustrate a few only of the numerous embodiments in which my invention may appear, selecting the forms shown from the standpoints of convenience in illustration, satisfactory operation and clear demonstration of the principles involved.

Figures 1 to 4 are conventional warpwise weave diagrams showing one sequence of weaving steps to produce a pile fabric in accordance with the invention.

Figures 1a to 4a are views similar to Figure 1 showing a variation, producing an improved :bind of the pile.

Figures lb to 4b are views illustrating diagrammatically in top plan the crowding effect as obtained in Figures 1 to 4 and Figures 1a to 4a. Figures 1b to 4b omit all ends which are below the mid-position and in this respect reflect the condition in the upper shed.

Figure 5 shows in a conventional warpwise weave diagram the completed weave of Figures 1 to 4.

Figure 5a shows in a conventional warpwise 'weave diagram of a completed weave of Figures 1a to 4a.

Figure 6 shows the thread-in in a particular dent in one form of the invention of Figures 1 to 4 and 1a to 4a. Figure 7 shows the thread-in in another form of the invention according to Figures 1 to 4 and 1a to 4a.

Figure 8 shows the thread-in in Figures 1 to 4 and 1a to 4a according to a preferred embodiment.

Figure 9 shows the thread-in of Figures la to 4:: accord- 2,891,582 Patented June 23, 1959 ing to an alternate embodiment which is very desirable.

Figure 10 is a top plan view showing the preferred thread-in in several different dents.

Figure 11 is a diagrammatic plan view of a fabric produced in accordance with the thread-in of Figure 10 and showing the crowding.

Figures 12, 13 and 14 are conventional warpwise completed weave diagrams showing the principles of the invention applied to weaving over transverse pile wires.

Figure 15 is a side elevation of a single pile yarn end which may be used as the face yarn.

In conventional pile fabric weaving practice, in order to obtain a pattern it is'necessary to use a jacquard mechanism and this correspondingly increases the investment, slows down the weaving and thus increases the cost of production of the fabric.

The present invention makes it possible to obtain pattern effects by weaving without a jacquard mechanism and thus using increased speeds and obtaining fabrics at reduced cost.

According to one of the principles of the invention, a plurality of pile warp ends are put in together in the same 'dent of the weave and the same eye of the heddle and woven together to cause rotation due to frictional engagement with the adjoining warp ends so that one particular pile warp end is predominant in one pile projection and another pile warp end is predominant in another pile projection. Thus there is a tendency for the ends to rotate back and forth and if they are of different colors or if they are of moresque yarn, pattern effects are produced.

According to one aspect of the invention, the pile projections are raised as terry loops and thus speed can be increased since wires are not used. In another form of the invention wires are employed and a jasp effect is obtained over Wires.

In accordance with the invention in one embodiment the pile warp end or ends in one dent or series of dents are placed on one side of the stuifer warp and in the next dent or series of dents are placed on another side of the stuffer warp. This leads to crowding which causes a buckling effect, producing texturing in the fabric, and the resulting texturing tends to obscure defects in weaving, such as lining, while at the same time giving a novel appearance to the fabric.

Considering first the simplified illustration of Figures 1 to 4, I there illustrate a series of steps in producing the weave of Figure 5.

In Figure 1 there are two pile warp ends 20 and 21 which are in the same dent or course in side by side relation and carried through the same eye of the heddle at each dent or course position. In Figure 1 these ends are fully raised and binder warp end 22 is raised half way, forming upper shed 23. The pile warp ends 24 and 25 carried side by side through the same dent or course and through the same eye of their heddle are lowered, as are binder warp ends 26 and stulfer warp ends 27, forming a lower shed 28. A shot of weft 30 is taken in the lower shed forming an upper weft.

In the next step, binder warp ends 26 remain lowered and all other warp ends are raised half-way as shown in Figure 2, forming a lower shed 28 in which a shot of lower weft 31 is inserted.

In the third step as shown in Figure 3, pile warp ends 24 and 25 are raised and binder warp ends 26 are raised half-way, forming an upper shed 23 and all other warp ends are lowered, forming a lower shed 28. A shot of upper weft 30 is taken in the lower shed.

In the fourth step as shown in Figure 4, binder warp ends 22 remain and all other warp ends are raised halfway, forming lower shed 28 in which a lower weft 31 is inserted.

By means of a special thread-in as shown in Figure 6 or 7 as later explained, the pile warp ends are forced up by the lay beating up a weft which by the grip of the other warp ends forces up the pile warp ends to form terry loops 32 from pile warp ends 20 and 21 woven together, and in the next row terry loops 33 from pile warp ends 24 and 25 woven together, the pile being bound by the upper wefts 30 as shown in Figure 5. This occurs even though no wires are inserted in the upper sheds.

In some cases it is preferable to obtain a tighter bind by binding beneath two upper wefts as in Figure a.

In Figure la pile warp ends 20 and 21 are raised, forming an upper shed 23, while pile warp ends 24 and 25, stuffer warp ends 27 and binder warp ends 22 raised half-way, and binder warp ends 26 are lowered, forming a lower shed 28. A shot of lower weft 31 is inserted in the lower shed.

In the next step, shown in Figure 2a, binder warp 26 is raised half-way and all other warps are lowered, forming a lower shed 28 in which an upper weft 30 is inserted.

In the third step as shown in Figure 3a, pile warps 24 and 25 are raised, forming an upper shed 23, pile warps 20 and 21, stuffer warp 27 and binder warp 26 are raised half-way, while binder warp 22 is lowered, forming a lower shed 28. A lower weft 31 is inserted in the lower shed.

In the fourth step as shown in Figure 4a, binder warp 22 is raised half-way and all other warps are lowered, forming a lower shed 28 in which an upper weft 30 is inserted.

Here again I will preferably weave a terry causing the pile warp ends to be forced up into loops 32' of Figure 5a for the pile warp ends 20 and 21 which pass through the same dents and same eyes of the heddle, and loops 33' for pile warp ends 24 and 25 which likewise pass through the same dents and through the same eyes of their heddles (although, of course, the eyes are different from those through which the pile warp ends 20 and 21 pass).

Weaving with two sets of pile warp ends in opposition as in Figure 5a, the pile warp ends are bound behind two upper wefts 30 before they again come up in the face of the fabric, whereas, if there are three sets of pile warps which form three rows in sequence, the pile warps are bound behind three upper wefts before they again come up to form pile. The alternate pile warp ends 20, 21 and 24, 25 are raised in the pile alternately.

The fabric of the invention is considerably improved by varying the thread-in so as to place the pile warp ends which are woven together on one side of the stufier in one dent or set of dents and on the other side of the stuifer in another dent or set of dents as shown in Figures lb to 4b.

In these figures the spits 34 of the reed are shown as well as the stuffer warps ends 27 and the pile warp ends, while the binder warp ends are only shown when they are in midposition. In dent or course 35, as shown in Figure 1b (in position similar to Figure la), pile warp ends 20 and 21 pass through the same eye 36 of their heddle and are located to the right of the stuffer warp end 27, while in the next dent or course 37 the pile warp ends 21 and 20 pass through the same eye 36 of the appropriate heddle together and are located to the left of the stuffer warp end 27.

As shown in Figure 2b (in position similar to Figure 2a), the binder warp end 26 is there raised by its heddle eye 38, and it is on the right of the stutter warp end dent 35, and on the right in dent 37. As shown in Figure 3b (which corresponds in position to Figure 3a), pile warp ends 24 and 25 are respectively on opposite sides of the stutter warp end in the two dents 35 and 37 and in each dent the pile warp ends 24 and 25 pass through the same eye 40 of the heddle manipulating these ends.

In the next step shown in Figure 4b (similar in position' to Figure 4a), the binder warp ends 22 are raised half-way by the eye 41 of their heddle. They are on the right of the stuifer warp end in each dent.

Thus, in summary, it will be seen that in Figure 1b where the pile warp ends are raised they are crowded together while in Figure 3b the other pile warp ends are widely separated. Of course in the next dentson either side a reverse condition prevails as the dents alternate in thread-in. This crowding effect tends to makethe pile form mounds or zones, which are thick buckles, aswill be later explained, imparting a contour or texture to the fabric. 7

In order to accomplish the terry weaving, an arrangement in the thread-in may be used which places the binders on the outside in a scissor arrangement in the dents, with the pile and stufier warp ends in between. It is possible in this connection to follow the principles of my US. Patent 2,714,399, granted August 2, 1955, for Terry Pile Weaving, and my Serial No. 369,815, filed July 23, 1953, now Patent No. 2,750,969, for Terry Pile Weave, incorporated herein by reference.

Figure 6 illustrates a thread-in which may be used for terry weaving according to these principles, the respective binder warp ends 22 and 26 adjoining the splits 34 at each side of the dent, while'pile warp end 20 is placed on one side of the stuffer warp end 27 and pile warp end 24 is placed on the other side of stuffer warp end 27 between the binder warp ends. If the jasp effect is to be used, end 20 will be replaced by two pile warp ends in the same eye and the same dent woven together and pile warp end 24 will be replaced by two pile warp ends in the same eye and the same dent woven together.

In some cases it is preferable to form the terry loop by using a thick pile weaving technique. This is illustrated in Figure 7, where in one dent 35 the binder end warp ends 22 and 26 are to the left of the stufier warp end 27. On the other hand the pile warp end or ends 20 are to the right of the stuffer warp end and next to the split in dent 35 and to the left. of the stutter warp end and next to the split in dent 37. Using the threadin of Figure 7 in order to raise the terry loop, it is necessary to operate within a certain size and pitch range. The number of plies of the pile-yarn end or ends should be between two and six and the number of turns per inch in the ply should be between /2 to 4. The number of turns in the single is not critical. The weight of the yarn should be between 20 and 50 yards per ounce. The pitch of the fabric (the number of courses in 27 inches) should be between and 220. If these precautions are taken with the thread-in asin Figure 7, where the pile warp ends are adjoining the split on opposite sides in adjoining dents, the frictional engagement of the adjoining pile warp ends forces them up into terry loops as in Figures 5 and 5a.

In the preferred embodiment, the thread-in will conform with Figure 8 which is well adapted to give the jasp effect or the rotational action to change the particular pile warp end at the top of the fabric which is predominant, and thus, where the ends are of different colors, or are moresque, to produce a pattern effect by chance. Here two pile warp ends 20 and 21 in the same heddle eye and woven together are placed to the left of the stuffer and two pile warp ends 24 and 25 in the same heddle eye and woven together are placed on the right, the binder warp ends being next to the splits.

In some cases two pile warp ends will be used together only on one pile warp set and in that case the thread-in will conform with Figure 9.

The jasp effect can best be understood by reference to Figure 10 which illustrates two heddles 42 and 43. In dents 35 and 37 the pile warp ends 20 and 21 are threaded through the same eye 36 of the heddle 43 and are carried together through the same dent of the reed to the right of the stufier warp 27, while in the next dents 35 and 36 the ends 20 and 21 are carried through to the left of the staffer warp end. In the next sequence they are again over to the right. On the other hand, the ends 24 and 25 are in just the reverse position in respect to the stuffer warp as they pass through the eyes 40 of their heddle 42. The stuffer warp is shown in the center but, of course, is not threaded through the eyes 36 and 40 but manipulated by a different heddle as well-known.

As the pile warp ends move up and down they are bound to rub against adjoining warp ends including the stuifer and the binder, and this produces the rotational action which has been described which brings certain ends on the top of the fabric into the most prominent position in certain pile projections.

On the other hand, it will be noted that the combination of the right and the left hand distribution of the pile warp ends on the top of the fabric with respect to the stuifer produces a crowding eflfect that is illustrated by Figure 11. Here a series of buckles or knobs 44 are shown which tend to consist of a dominant height 45, an area of intermediate height 46, and an irregular low defining edge 47. Thus, in efiect, these mound-like forms extend throughout the fabric and give a texturing without the necessity of using wires and without the necessity of providing any variation in height in the wires, if wires are used. The texturing is due to the crowding and the change in appearance is accentuated by the jasp effect on account of the rotation.

While the discussion thus far has referred to the forming of the tufts or loops by terry weaving, I illustrate in Figures 12 to 14 weaves which are accomplished by carrying two pile warp ends together through the same dent and the same eye of the heddle and weaving over wires 48 which may, of course, be straight, wavy, cutting, non-cutting, cutting and non-cutting, flag, high and low, or any other suitable combination. Figure 12 illustrates two sets of pile warp ends woven in opposition and alternately raised in the pile to form pile projections 50 and 51 in sequence bound behind the upper wefts 30. Depending on the rotation which produces the jasp effect, a particular pile warp end will be prominent in one tuft and another pile warp end will be prominent in another tuft.

Figure 13 shows a single frame or set of pile warps woven over wires 48 but with two pile warp ends carried together to obtain the jasp effect.

Figure 14 is a diagram illustrating a two-pile fabric woven over wires and producing theoretical areas of pile projections 50' and 51' but due to the rotational effect the actual positions of the particular pile Warp, ends varies in different loops as shown at 51 and 51 sometimes prominent and other times subordinate.

The jasp effect can be accentuated by using a moresque yarn end for each of the pile warp ends as shown in Figure 15, this consists of two or more plies 52 and 53 of different colors twisted together to produce a moresque. Thus in a yarn of this character the rotational action causes not only a change in each pile warp end which is predominant but also causes a different color to show on the same pile warp end.

In view of my invention and disclosure, variations and modifications to meet individual whim or particular need will doubtless become evident to others skilled in the art, to obtain all or part of the benefits of my invention Without copying the method and fabric shown, and I, therefore, claim all such insofar as they fall within the reasonable spirit and scope of my claims.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is:

1. The method of weaving a pile fabric, which comprises threading-in through the same eye of the heddle and the same dent of the reed at least two pile warp ends running longitudinally side by side and of different visual appearance, raising the pile warp ends and lowering other warp ends to form a shed, inserting a shot of weft in the shed, holding the pile warp ends up to form pile loops, lowering the pile warp ends and raising other warp ends to form a second shed, inserting a shot of weft in the second shed, and rotating the pile warp ends in the same eye and dent by the raising and lowering of the pile warp ends and the frictional engagement with adjoining ends to establish with variation by chance which of the ends of different visual appearance in loops are exposed to outside view of the pile.

2. The method of claim 1, in which there are stuifer warp ends in the dents, which comprises threading in the corresponding pile warp ends of a particular frame in some dents on one side of the stuifer warp end and in other dents on the other side of the stutter warp end, and thus producing a buckling effect in the fabric.

3. The method of claim 2, which comprises threading-in the pile warp ends of a particular frame in one dent or dents on one side of the stuffer warp end and in the next dent or dents on the other side of the stuifer warp end in a series of groups across the fabric.

4. The method of claim 1, in which the pile warp ends are forced up by pressure of neighboring warp ends as terry loops.

5. The method of claim 1, in which the pile warp ends are held up over wires.

6. The method of claim 1, which comprises weaving in opposition to one another at least two frames of pile warp ends having the thread-in of claim 1.

7. The method of claim 1, which comprises forming the pile from a single frame.

References Cited in the file of this patent UNITED STATES PATENTS 731,433 Cookson June 23, 1903 873,744 Hardwick Dec. 17, 1907 1,848,069 Wilson Mar. 1, 1932 1,953,720 Nutter Apr. 3, 1934 2,571,077 Underwood et a1. Oct. 9, 1951 2,702,056 Hoeselbarth Feb. 15, 1955 2,713,355 Hoeselbarth July 19, 1955 2,714,399 Hoeselbarth Aug. 2, 1955 2,754,850 Hoeselbarth July 17, 1956 FOREIGN PATENTS 500,301 Great Britain June 17, 1938 

